Variable area nozzle assisted gas turbine engine restarting

ABSTRACT

A turbofan engine starting system includes a core nacelle housing ( 12 ), a compressor ( 16 ) and a turbine ( 18 ). The core nacelle is disposed within a fan nacelle ( 34 ). The fan nacelle includes a turbofan ( 20 ). A bypass flow path (B) downstream from the turbofan is arranged between the two nacelles. A controller ( 50 ) is programmed to manipulate the nozzle exit area (A) of the bypass flow path to facilitate startup of the engine. In one example, the controller manipulates the nozzle exit area using hinged flaps ( 42 ) in response to an engine shutdown condition. The flaps open and close to adjust the nozzle exit area and the associated bypass flow rate, the mass flow rate of the air through the cave nacelle and the rotational speed of the compressor rotar ( 14 ).

BACKGROUND OF THE INVENTION

This invention relates to starting gas turbine engines, and, more particularly, to facilitating gas turbofan engine restarts by effectively altering the nozzle exit area.

Gas turbine engines are widely known and used for power generation and vehicle (e.g., aircraft) propulsion. During in-flight propulsion of a multi-engine aircraft, certain problems may occur with one engine causing the engine to shut down. For example, inclement weather, non-optimum trimming of engine idle, fuel nozzle coking, fuel contamination, loss of electric power, fuel mismanagement, pilot error, or the like may, under certain conditions, warrant voluntary or automatic shut down of an engine. Although the remaining engines can typically fly the aircraft, it is ordinarily desired to restart the shut down engine while the aircraft is still in-flight.

An engine restart envelope includes combinations of aircraft altitude and airspeed that provide a suitable air supply to the engine sufficient for restarting. When traveling outside of the engine restart envelope, the air supply to the engine may not contain enough oxygen to support combustion during ignition. In some instances, starter-assistance may be used to increase the rotational speed of a fan section of the engine, which increases altitude and airspeed combinations suitable for restarting the engine. Increasing the rotational speed of the fan section draws additional airflow into the engine and, in so doing, augments the supply of oxygenated air supporting combustion.

Disadvantageously, at certain combinations of altitude and airspeed, increasing the rotational speed of the fan section is not alone sufficient to generate adequate airflow to support combustion. As a result, aircraft experiencing in-flight shutdown may have to rapidly adjust altitude and/or airspeed to move within the engine restart envelope or starter-assisted engine restart envelope. As an example, if an engine requires restart in aircraft traveling at an altitude unsuitable for engine restarts, the aircraft may rapidly decrease elevation to move to an altitude suitable for restarting the turbofan engine. Alternatively, the aircraft may be forced to continue flying, without propulsion from the shutdown engine.

What is needed is a method capable of restarting the turbofan engine through an increased number of altitudes and airspeeds.

SUMMARY OF THE INVENTION

An example turbofan engine starting system includes a core nacelle housing a compressor and a turbine. The core nacelle is disposed within a fan nacelle. The fan nacelle includes a turbofan. A bypass flow path downstream from the turbofan is arranged between the two nacelles. A controller is programmed to manipulate the nozzle exit area to facilitate startup of the engine. In one example, the controller manipulates the nozzle exit area using hinged flaps in response to an engine shutdown condition. The hinged flaps open and close to adjust the nozzle exit area and the associated bypass flow rate.

An example method for starting the engine includes detecting an engine shutdown and changing the effective nozzle exit area during a restart procedure to facilitate restarting the engine. In one example, the method includes adjusting the nozzle exit area to increase the windmilling speed of a fan section of the turbofan engine and decreasing the nozzle exit area to increase the mass flow rate of air through the core nacelle.

These and other features of the present invention can be best understood from the following specification and drawings, the following of which is a brief description.

BRIEF DESCRIPTION OF THE DRAWINGS

The various features and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the currently preferred embodiment. The drawings that accompany the detailed description can be briefly described as follows.

FIG. 1 illustrates selected portions of an example gas turbine engine system.

FIG. 2 illustrates a variable air nozzle and coolant passage within the gas turbine engine system shown in FIG. 1.

FIG. 3 illustrates an example turbofan engine restart envelope without assistance from a variable area nozzle.

FIG. 4 illustrates an example turbofan engine restart envelope with assistance from a variable area nozzle.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

A geared turbofan engine 10 is shown in FIG. 1. The engine 10 includes a core nacelle 12 that houses a low rotor 14 and high rotor 24. The low rotor 14 supports a low pressure compressor 16 and low pressure turbine 18. In this example, the low rotor 14 drives a fan section 20 through a gear train 22. The high rotor 24 rotationally supports a high pressure compressor 26 and high pressure turbine 28. A combustor 30 is arranged between the high pressure compressor 26 and high pressure turbine 28. The low and high rotors 14, 24 rotate about an axis X. At least a portion of the core nacelle 12 is disposed within a fan nacelle 34.

In the examples shown, the engine 10 is a high bypass turbofan arrangement. In one example, the bypass ratio is greater than 10, and the turbofan diameter is substantially larger than the diameter of the low pressure compressor 16. The low pressure turbine 18 has a pressure ratio that is greater than 5, in one example. The gear train 22 can be any known suitable gear system, such as a planetary gear system with orbiting planet gears, planetary system with non-orbiting planet gears, or other type of gear system. It should be understood, however, that the above parameters are only exemplary of a contemplated geared turbofan engine. That is, the invention is applicable to other types of engines.

For the engine 10 shown FIG. 1, a significant amount of thrust may be provided by the bypass flow B due to the high bypass ratio. Thrust is a function of density, velocity, and area. One or more of these parameters can be manipulated to vary the amount and direction of thrust provided by the bypass flow B. In one example, the engine 10 includes a nozzle structure 38 associated with the nozzle exit area A to change the physical area and geometry to manipulate the thrust provided by the bypass flow B. However, it should be understood that the nozzle exit area A may be effectively altered by other than structural changes, for example, by altering a boundary layer of the bypass flow B. Furthermore, it should be understood that effectively altering the nozzle exit area A is not limited to physical locations approximate to the exit of the fan nacelle 34, but rather, includes altering the bypass flow B by any suitable means at any suitable location of the fan section 20.

In the example shown in FIG. 2, an engine restart system 54 includes multiple hinged flaps 42 arranged circumferentially about the rear of the fan nacelle 34. The hinged flaps 42 form a portion of a control device 41, which further includes a controller 50 in communication with actuators 46 used to manipulate the hinged flaps 42. A detector 52 communicates information about the engine 10 to the controller 50, for example, information that the engine 10 has shut down or relating to the startup state of the engine 10. In one example, the detector 52 monitors the rotational speed of the low rotor 14, which is indicative of the state of the engine 10. The controller 50 interprets rotational speeds of the low rotor 14 below a certain level as a condition of the engine 10 indicting the engine 10 has shut down. In another example, the detector 52 monitors fuel consumption of the engine 10. If the engine 10 experiences a drop in fuel consumption, the detector 52 communicates this information to the controller 50, which interprets the information as a shutdown of the engine 10. The detector 52 may be located proximate or apart from the engine 10. The controller 50 also communicates with a driver 56, which may be controlled by an aircraft operator. Thus, the controller 50 may operate automatically using information from the detector 52, or may operate manually based on signals from the driver 56. A starter 58, such as a hydraulic starter, may be used to boost the rotational speed of the fan section 20.

The hinged flaps 42 can be actuated independently and/or in groups using segments 44. The segments 44 and individual hinged flaps 42 can be moved angularly using actuators 46. The control device 41 thereby varies the nozzle exit area A (FIG. 1) between the hinged flaps 42 and the engine 10 by altering positions of the hinged flaps 42. In a closed position, the hinged flap 42 is closer to the core nacelle 12 for a relatively smaller nozzle exit area A. In an open position, the hinged flap 42 is farther away from the core nacelle 12 for a relatively larger nozzle exit area A.

When the engine 10 shuts down during flight, the fan section 20 will continue to rotate, or windmill, as the engine 10 moves, either by gliding or powered by additional engines. Restarting the engine 10 requires adequate compressed air to support combustion. Changing the nozzle exit area A influences the mass flow rate of airflow over the fan section 20 as a function of radial distance from the axis X. For example, increasing the size of the nozzle exit area A increases the bypass flow B. This decreases the mass flow rate of the airflow over the fan section 20 at radial distances near to the axis X and increases the mass flow rate of the airflow over the fan section 20 at radial distances away from the axis X. The increased mass flow rate exerts more force on radially outward portions of the fan section 20 to accelerate rotation of the fan section 20. Thus, by controlling bypass flow B the rotational speed of the fan section 20 is controlled.

As an example, it is estimated that moving the hinged flaps 42 from a location suitable for aircraft cruising operations to an open position increases the windmilling speed of the fan section 20 about 10-20%. Increasing the windmilling speed of the fan section 20 also increases the rotational speed of the low rotor 14, the low speed compressor 16, and the low pressure turbine 18.

Inversely, decreasing the size of the nozzle exit area A increases the mass flow rate of the air through the core nacelle 12. As a result, after increasing the fan section 20 windmilling speed, the hinged flaps 42 move to a closed position to decrease the nozzle exit area A and thereby increase airflow through the core nacelle 12. Rotational inertia of the fan section 20 forces airflow into the core nacelle 12. The rotational inertia also contributes to rotating the low pressure compressor 16, which compresses air in preparation for ignition. In this example, the controller 50 monitors the rotational speed of the low rotor 14 to determine an appropriate time to decrease the size of the nozzle exit area A.

In an example method of restarting the engine 10, communications from the controller 50 open the hinged flaps 42 to maximize the windmilling speed of the rotating fan section 20, which also increases the rotational speed of the low rotor 14. Next, communications from the controller 50 direct the hinged flaps 42 to close, which increases the mass flow rate of airflow through the core nacelle 12. Rotational inertia remaining in the windmilling fan section 20 helps to compress the increased airflow through the core nacelle 12. If not for the rotational inertia in the windmilling turbofan, airflow would only move through the engine 10 at a rate corresponding to the closed position of the hinged flaps 42. The rotational inertia in the windmilling fan section 20 increases airflow above this rate increasing the supply of oxygenated air available for combustion. Actuating the hinged flaps 42 in this way during the engine 10 restart increases the combinations of altitudes and airspeeds suitable for restarting the engine 10. After reaching a sufficient level of compressed air, fuel flow is introduced to the compressed air, and the mixture is ignited, thereby restarting the engine 10.

Referring now to FIG. 3 with continued reference to FIG. 1, illustrated is a typical flight envelope 60 for the engine 10, that is, those combinations of altitude and airspeed suitable for operating the engine 10. Within the flight envelope 60, an area 64 represents combinations of altitude and speed suitable for restarting the engine without effectively altering the nozzle exit area A. FIG. 4 represents an increased area 68 illustrating the combinations of altitude and speed suitable for restarting the typical engine when altering the nozzle exit area A. Formerly, the engine 10 may have needed starter assistance to restart at some of the altitudes and speeds included in area 68. Of course, starter assistance may increase the likelihood of restarting the engine 10 at altitudes and airspeeds beyond those included in area 68.

In the disclosed examples, the ability to control the amount of airflow through the nozzle exit area A provides the benefit of restarting the engine 10 while in flight at increased combinations of altitudes and airspeeds. Restarts in prior designs may have required starter assistance for similar restarts. Further, although described in terms of restarts while in the air, adjusting nozzle exit area A (FIG. 1) may also be used to facilitate starting the engine 10 while on the ground.

Although a preferred embodiment of this invention has been disclosed, a worker of ordinary skill in this art may recognize certain modifications falling within the scope of this invention. For that reason, the following claims should be studied to determine the true scope of coverage for this invention. 

1. A turbofan engine restarting system, comprising: a core nacelle housing a compressor and a turbine; a fan nacelle housing a fan section that is arranged upstream from said core nacelle; and a bypass flow path downstream from said fan section and arranged between said core and fan nacelles, said bypass flow path including an effective nozzle exit area that defines an axis; and a controller programmed to selectively increase and decrease said effective nozzle exit area to facilitate restart of said engine during flight in air.
 2. The turbofan engine restart system of claim 1, wherein a plurality of flaps are arranged about the axis, said controller initiates movement of at least some of said flaps radially away from said axis to increase said effective nozzle exit area, and initiates movement of at least some of said flaps radially toward said axis to decrease said effective nozzle exit area.
 3. The turbofan engine restart system of claim 1, including a control device arranged to receive a command from said controller in response to an engine condition, said control device changing said effective nozzle exit area provided between said core and fan nacelles in response to said command.
 4. The turbofan engine restart system of claim 3, wherein said control device increases or decreases said effective nozzle exit area in response to said command.
 5. The turbofan engine restart system of claim 3, wherein said control device increases a mass flow rate of air through said bypass flow path.
 6. The turbofan engine restart system of claim 3, wherein an increased mass flow rate of air through said bypass flow path increases a windmilling speed of said fan section.
 7. The turbofan engine restart system of claim 3, comprising a driver for initiation by an aircraft operator and in communication with said controller, said controller sending said command in response to actuation of said driver.
 8. The turbofan engine restart system of claim 3, wherein said engine condition includes a rotational speed of a portion of said engine.
 9. The turbofan engine restart system of claim 1, including at least one nozzle flap disposed on said fan nacelle operative to control said effective nozzle exit area.
 10. The turbofan engine restart system of claim 1, including a starter for increasing a rotational speed of said fan section.
 11. A method of restarting a turbofan engine comprising the steps of: a) detecting a shutdown of a turbofan engine during flight in air; and b) selectively increasing and decreasing effective nozzle exit area from a bypass flow path within the engine in response to the shutdown to establish a desired condition for a startup of the engine.
 12. The method of restarting a turbofan engine according to claim 11, wherein changing the effective nozzle exit area is achieved by changing a physical area of an exit nozzle, the exit nozzle provided by a turbofan nacelle surrounding a fan section and a core nacelle.
 13. The method of restarting a turbofan engine according to claim 11, wherein a controller commands a control device to change the effective nozzle exit area.
 14. The method of restarting a turbofan engine according to claim 13, wherein the controller commands the control device based on a rotational speed of a rotor.
 15. The method of restarting a turbofan engine according to claim 13, wherein the controller commands the control device based on at least one of an airflow rate or an air pressure within the engine.
 16. The method of restarting a turbofan engine according to claim 11, wherein said step (b) includes increasing the effective nozzle exit area to increase a rotational speed of a rotor within the engine.
 17. The method of restarting a turbofan engine according to claim 11, wherein said step (b) includes decreasing the effective nozzle exit area to increase a mass flow rate of air through a portion of the engine.
 18. The method of restarting a turbofan engine according to claim 11, wherein said step (b) includes increasing the effective nozzle exit area and then decreasing the effective nozzle exit area to the increase mass flow rate of air through a portion of the engine.
 19. The method of restarting a turbofan engine according to claim 11, including: c) increasing the rotational speed of a fan section of the engine using a starter. 